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Recommendations for Evaluating & Implementing Proximity Warning /-~,/-,< ,, --!~~(; ,t\f Workplace Safety and Health Recommendations for Evaluating & Implementing Proximity Warning Systems on Surface Mining Equipment Department of Health and Human Services Centers for Disease Control and Prevention National Institute for Occupational Safety and Health ~/OSH (J ~ r/- CcJ,,(,1/tf - 7-::?_ Report of Investigations 9672 Recommendations for Evaluating and Implementing Proximity Warning Systems on Surface Mining Equipment T. Ruff DEPARTMENT OF HEALTH AND HUMAN SERVICES Public Health Service Centers for Disease Control and Prevention National Institute for Occupational Safety and Health Spokane Research Laboratory Spokane, WA June 2007 This document is in the public domain and may be freely copied or reprinted. DISCLAIMER: Mention of any company or product does not constitute endorsement by the National Institute for Occupational Safety and Health (NIOSH). In addition, citations to Web sites external to NIOSH do not constitute NIOSH endorsement of the sponsoring organizations or their programs or products. Furthermore, NIOSH is not responsible for the content of these Web sites. ORDERING INFORMATION To receive documents or other information about occupational safety and health topics, contact NIOSH at NIOSH-Publications Dissemination 4676 Columbia Parkway Cincinnati, OH 45226-1998 Telephone: 1-800-35-NIOSH Fax: 513-533-8573 e-mail: [email protected] or visit the NIOSH Web site at www.cdc.gov/niosh DHHS (NIOSH) Publication No. 2007-146 July 2007 SAFER • HEALTHIER • PEOPLE™ Contents Abbreviations ........................................................................................ viii Abstract .............................................................................................. ix Acknowledgments .................................................................................... x 1 Introduction ....................................................................................... 1 2 Problem ............................................................................................. 3 2.1 Recent Accidents .......................................................................... 3 2.2 Equipment Blind Areas ................................................................. 4 3 Approach .................................................................................... 7 3.1 Technology Assessment ................................................................. 7 3.1 .1 Radar ................................................................................ 7 3.1 .2 Sonar ................................................................................ 8 3.1 .3 Infrared ............................................................................. 8 3.1.4 Tag-based ......................................................................... 9 3.1.5 System Selection ................................................................ 9 3.2 Preliminary Test ........................................................................... 10 3.3 Field Test ................................................................................... 11 3.4 New Technology Development ..................................................... 11 4 Test Summaries ................................................................................ 13 4. 1 Preview Heavy Duty Radar ........................................................... 1 3 4 .2 Ogden Radar System .................................................................. 1 8 4.3 Advanced Mining Technology CAS-CAM/RF System ........... .-.......... 21 4.4 Ultra-wideband Radar ................................................................. 24 4.5 GPS-based Proximity Warning ..................................................... 27 4.6 Computer-based Stereo Vision ..................................................... 30 4. 7 HASARD System ......................................................................... 31 4.8 Nautilus Buddy System ................................................................ 32 4.9 System Manufacturers ................................................................. 34 Evaluating Proximity Warning Systems on Surface Mining Equipment iii Table of Contents 5 Recommendations ........................................................................... 37 5.1 Choosing a Technology .............................................................. 37 5 Recommendations continued 5.2 Mounting Considerations ............................................................ 39 5.3 Video Cameras .......................................................................... 40 5.4 Alarm Presentation ..................................................................... 42 5.5 Training ..................................................................................... 43 5.6 Economics ................................................................................. 44 5.7 Future Research .......................................................................... 44 6 Summary ......................................................................................... 4 7 References ........................................................................................... 4 9 Appendices .......................................................................................... 53 A Blind Area Diagrams ......................................................................... 53 Al Euclid EH4500 280-ton-capacity dump truck ................................. 53 A2 Blind area diagram for a Euclid EH4500 280-ton-capacity haul truck (ground plane) ............................................................. 54 A3 Blind area diagram for a Euclid EH4500 280-ton-capacity haul truck (l .5 meter plane) .......................................................... 55 A.4 Caterpillar 992G front-end loader ................................................. 56 AS Blind area diagram for a Caterpillar 992G front-end loader (ground plane) .................................................................. 57 A.6 Blind area diagram for a Caterpillar 992G front-end loader (l .5 meter plane) ............................................................... 58 A7 Hitachi EXSS00 excavator ............................................................. 59 AS Blind area diagram for an Hitachi EXSS00 excavator. (ground plane) ............................................................................. 60 A9 Blind area diagram for an Hitachi EXSS00 excavator. (1.5 meter plane) ......................................................................... 61 A. l 0 Caterpillar Dl l R dozer ............................................................... 62 All Blind area diagram for a Caterpillar Dl l R dozer (ground plane) ........................................................................... 63 A 12 Blind area diagram for a Caterpillar Dl l R dozer (1.5 meter plane)··························································:············ 64 A 13 Caterpillar 16G motor grader ..................................................... 65 IV Evaluating Proximity Warning Systems on Surface Mining Equipment Table of Contents A.14 Blind area diagram for a Caterpillar 16G motor grader (ground plane) ........................................................................... 66 A.15 Blind area diagram for a Caterpillar 16G motor grader (1.5 meter plane) ....................................................................... 67 B. Procedures for Determining the Detection Characteristics of a Proximity Warning System ............................................................ 69 Bl. l Definitions ................................................................................. 69 Bl .2 Test Obstacles ............................................................................ 70 Test Procedure continued Bl .3 Test Setup .................................................................................. 70 Bl .4 Test Procedures .......................................................................... 70 Bl .4.1 Testing for False Alarms .................................................... 70 Bl .4.2 Testing Obstacle Detection ............................................... 71 Bl .5 Recording Data .......................................................................... 72 C. Data Collection Form ....................................................................... 75 D. System Manufacturers and Distributors ............................................... 77 01. l Radar-based Systems .................................................................. 77 D 1.2 Sonar-based Systems .................................................................. 77 D 1.3 Infrared Sensors and Thermal Imaging ......................................... 77 D l .4 Tag-based Systems ..................................................................... 78 D 1.5 Video Systems ............................................................................ 78 List of Tables Table l Fatal accidents in surface mines partially attributed to blind areas around equipment ................................................................... 3 Table 2 Radar alarm data .................................................................. l 7 Table 3 Proximity warning technology characteristics ............................ 37 List of Figures Figure l. An example of a radar-based proximity warning system (early version of the Preview radar system by Preco Electronics) . 7 Figure 2. An example of a sonar or ultrasonic sensor-based proximity warning system (Hindsight
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